EP1216866B1 - Lightweight door for motor vehicles - Google Patents

Abstract

The lightweight car door has a window frame (5) consisting of an extruded and bent aluminum or aluminum alloy profile. This has peripheral grooves (6, 7) into which a mounting strip (8) fits, allowing other components, e.g. a sealing strip (9), to be fitted. An Independent claim is included for a method for making the door.

Description

The invention relates, according to the preamble of Anpruchs 1 disclosed in DE 196 16788 A, the construction of a lightweight door for motor vehicles, d. H. a shell door, the after the painting process later with more Installations such as windows, door inner lining etc. is completed.

The design of doors for motor vehicles is subject to various requirements certainly. These are z. Static stiffness requirements, dynamic stiffness requirements and space requirements and arrangement of built-in parts. Static stiffness requirements are For example, the requirements for the window frame with respect to bending and torsion and the overall door requirements for lowering and suppression. Dynamic rigidity requirements result from the security requirements for frontal and side crash and more Requirements for occupant protection. The room requirements apply the practicable installation and operation of mounted and functional parts in or at the door, adherence to open spaces for assembly work, compliance from minimum distances to moving parts, the distance keeping parallel surfaces, in particular for sealing purposes, the division of the interior the door in dry room and damp room etc.

The previously listed requirements for doors for motor vehicles are principle, regardless of which constructive way the door of the Motor vehicle is designed.

So far, sheet steel is the most common raw material for automotive doors. The conventional technique of a solid-color door in shell technology is known. This consists of two punching cups and glass channel frames, which together be connected, wherein on the inner shell later installation components be grown.

Another conventional door concept is represented by the frame door. The frame door consists of a roll-profiled and stretch-bent Steel window frame welded or bolted to a door box is. The door box itself is in turn composed of two die-cut shells, which are interconnected.

With regard to the formation of variants is useful a frame door with a in the door box welded window frame (modular system door). Such Steel door for motor vehicles is for example from EP 0 476 351 A1 known. This construction method can be used for different vehicle types some same components are used.

It has been shown that the previously explained modular system door also made Light metal / light metal alloys, in particular aluminum alloys can be produced. A corresponding example, the closest State of the art represents, results from DE 196 16 788 A1. The disclosed lightweight door for motor vehicles has a door outer panel and a support frame, wherein the support frame has a U-leg forming hinge carrier, one forming the other U-leg Lock carrier and has a U-web forming door bottom. Of the Hinge carrier and the lock carrier are castings of a light metal alloy, in particular an aluminum alloy produced during the this connecting door floor as an extruded profile, stamped profile or roll profile made of a light metal alloy, in particular an aluminum alloy is. Closed at the open side of the U is the support frame through outer and inner window channel profiles, which also as aluminum extrusion profiles can be executed. Window guidance profiles and Hinge reinforcements complete the frame construction of this Lightweight door. The design of the hinge carrier and the lock carrier as Alloy casting allows the realization of complex shapes, but is costly.

In the previously explained, known from the prior art lightweight door can the surrounding the window area, with the door box permanently connected window frames as extruded and bent, in particular stretch-bent light metal profile be executed (see also DE 40 08 111 A1). This initially uncovered window frame must be different Attachment parts are provided. These include gaskets as well as a inner roof trim panel with clips or with fastening plugs (this requires drilling) is attached. This includes one outside to be attached frame cover and a cover for the B-pillar.

The use of a variety of attachments on and around the window area a door of a motor vehicle requires a high assembly cost. The various attachments must be matched and carefully assembled of course, with the tolerances of the items naturally adding up can, which can sometimes lead to disturbing large gap widths and the appearance is impaired.

A window frame module for the production of motor vehicle doors is known (DE 197 27 010 A1), which is also constructed three main modules, namely the actual Window frame, one of the inside of the door facing frame panel, the window frame is attached, and to be arranged on the window frame sealing module. As a result, the number of attachments is reduced, the cost of construction is still significant. The actual window frame exists only partially from an extruded light metal profile. Namely, it includes two light metal die casting parts as side parts in A-pillar and B-pillar and a these side parts on the upper side connecting frame arch, which then an extruded and curved light metal profile. There in the roof area has this section of the Window frame a closed hollow chamber, on the outside of a mounting strip for the sealing module is molded. In the vertical sections at A-pillar and B-pillar you will not find such a hollow chamber, but U-shaped formations.

The invention is based on the problem of the initially explained lightweight door in terms to optimize the design of the window frame. This solves the present Teaching with the features of claim 1. Thus, the necessary Mounting options provided on the window frame, especially under Consideration of the requirements for mounting an aperture module. Of the continuous window frame gains its rigidity through the closed hollow chamber, at which then the receiving groove and / or the mounting strip formed are located. In it is then attached as an essential attachment the aperture module outside.

Preferred embodiments and developments of the basic teaching The invention are the subject of the dependent claims.

Fig. 1

eine Sprengdarstellung einer erfindungsgemäßen Leichtbautür in der Ausführung als vordere Seitentür bei bereits fertiggestelltem Türkasten mit montiertem Fensterrahmen,

Fig. 2

einen Schnitt aus Fig. 1 entlang der Linie II-II,

Fig. 3

einen Schnitt aus Fig. 1 entlang der Linie III-III,

Fig. 4

einen Schnitt aus Fig. 1 entlang der Linie IV-IV.

In the following the invention will be explained in more detail with reference to a drawing showing only one embodiment. In the drawing shows

Fig. 1

an exploded view of a lightweight door according to the invention in the embodiment as a front side door in already finished door box with mounted window frame,

Fig. 2

a section of Figure 1 along the line II-II,

Fig. 3

a section of Figure 1 along the line III-III,

Fig. 4

a section of Fig. 1 along the line IV-IV.

The present patent application is related to a simultaneous filed patent application, which deals with the construction of a Total lightweight door, especially in the area of the door handle.

Fig. 1 shows an example of a lightweight door for a motor vehicle front Side door, namely the passenger door. This lightweight door for motor vehicles initially has a door box 1. For the door box 1 is under the Teaching the present patent application initially only of importance that He upwards to the window area through inner and outer window sill profiles 3, 4 (Fig. 4) is limited. In principle, come for the present Doctrine so door boxes 1 by any design in question. The illustrated and In this respect preferred door box 1 of the illustrated embodiment relates a particularly easy-to-build construction, which is a substantially U-shaped support frame 1 'with hinge support, lock carrier, door bottom and having a part of the door inner panel. Subject of the parallel patent application is the design of this support frame 1 'as one piece, from a Sheet metal with minimum sheet metal thickness of light metal / light metal alloys produced pressed part or deep drawn part. At this is the outside door planking 2 attached.

The lightweight door is completed with a window surrounding the area, with the door box 1, in particular with the inner window shaft profile 3 of the door 1, permanently connected, namely in particular welded Window frame 5 made of light metal / light metal alloys, in particular Aluminum / aluminum alloys. The window frame 5 is shown in FIG. 1 already firmly connected to the door box 1 and forms with the door box. 1 Together, the shell of the lightweight door to which all other parts attached become.

The window frame 5 is as extruded and bent, in particular stretch-bent light metal profile executed. The window frame 5 is preferably a continuous profile, but can also consist of two profile sections be composed. You can, for example, two curved Extrusions converge in the upper corner facing the B-pillar let and miter cut. This is occasionally required if design requirements for a sharp-trained there Demand a corner.

The cross section of the window frame 5 can be seen with reference to FIG. 2 and FIG. 3 understand well. The position of the sections according to FIGS. 2 and 3 is shown in FIG Fig. 1 shown. It turns out that the cross-section of the extruded Alloy profile, which forms the window frame 5, in its course not changed. The longitudinal contour only has cross-sectional changes to that extent than when they were further processed, such as notches, be induced after bending.

It is essential that on the window frame 5 forming light metal profile at least one profile profile following, essentially continuous Receiving groove 6; 7 and / or at least one following the profile course, is formed substantially continuous slip-8, the for receiving, attaching or connecting an attachment 9; 10; 11; 27 serves.

The grooves 6; 7 and the slip-8 on the window frame 5 create the conditions that the necessary attachments quickly and easily without further drilling o. The like. Attached to the window frame 5 can be. More on that later.

The necessary torsional rigidity of the window frame 5 accomplishes this illustrated light metal profile through a closed hollow chamber 12, to then outside the receiving groove 6; 7 and / or the mounting strip 8 is formed is or are.

The illustrated and preferred embodiment is shown in Fig. 2 indicated the door frame 13 in the roof area and a window pane 14, in Fig. 3, the B-pillar 15 of the vehicle body with attached body side Seal 16 and also the window pane 14. In FIG. 2 and FIG. 3 it can be seen that a first T-shaped groove 6 for attaching a door-side main seal 9 is provided as a first attachment. The Seals are always displayed in a relaxed state, so be by the also drawn, opposite sealing surface in the sealing, elastically deformed state. This explanation facilitates the understanding of the representations.

Another T-shaped receiving groove 7 on the window frame 5 is the attachment of fasteners of attachments 10; 11, the later will be explained in detail. This second receiving groove 7 is shown in the Embodiment obliquely relative to the first receiving groove. 6 arranged on the hollow chamber profile 12 of the light metal profile.

Fig. 2 also shows that in the illustrated and preferred embodiment on the further existing slip 8 an additional Seal 17 is attached, which in the area of the roof frame 13 the occurrence Wind noise and water ingress prevented.

The illustrated and preferred embodiment of the window frame 5 forming light metal profile shows the slip-8 approximately at right angles angled from the receiving groove 6 for the main seal 9, so that an excellent free space for the arrangement of the main seal. 9 as well as for the additional seal 17 results.

Fig. 3 also shows that the slip-8 in this area, ie at the B-pillar 15, no longer carries the seal 17, but for another Purpose is needed, which will be explained later.

Fig. 1 further makes clear in connection with Figs. 2 and 3 that the teaching the invention be perfected with a special further measure can, namely by the fact that as an attachment as a plastic molding, in particular plastic injection molded part, designed aperture module 10 of outside the window frame 5 is mounted and that in the aperture module 10 in one piece the outer panels 19; 20 on the roof frame 13 and on the B-pillar 15 are formed and the diaphragm module 10, at least one window guide seal 21 is attached. In both figures you can see the Fensterfuhrungsdichtung 21 for guiding the window pane 14 embedded in a corresponding recording of the aperture module 10th

Fig. 4 shows that the diaphragm module 10 in the illustrated embodiment Also, the outer window seal 22 is attached. Moreover, here is also to recognize an inner window gasket 18, the inner Window shaft profile 3 is mounted.

Figs. 2 and 3 show that the diaphragm module 10, at least in the circumferential Edge area, designed in cross-section as a U-profile with subsequent L-profile is. The U-profile forms the receptacle for the window guide gasket 21, the profile forms the receptacle for the additional seal in the roof area 17 on the mounting strip 8 of the window frame 5. This is by means of additional L-shaped profile, which in turn through the web of the U-profile to a U-profile has been completed, the attachment of the aperture module 10th ensured by plugging in the roof area.

For attachment of the diaphragm module 10 is further provided that this for Attachment to the window frame 5 with a support surface 23 on a contact surface of the window frame 5 forming light metal profile is applied and with Help a plurality of spaced clamps 24 is fixed in the receiving groove 7 of the light metal profile. there it is envisaged that the clamping brackets 24 as metal spring clips are executed, one recognizes these metal spring clips 24 well in Fig. 2nd

Fig. 1 finally shows that the diaphragm module 10 with in the door box. 1 plug-in extensions of the window guides 25 is provided in the Door box 1 are anchored.

In the diaphragm module 10 is in the illustrated embodiment still a Mirror triangle 26 integrated.

The summary of a plurality of apertures 19; 20; 26 and seals 21; 22 in the diaphragm module 10 eliminates a variety of problems in the prior art with the large number of parts to be attached were connected. So you can just the aperture module 10, the rule just made of plastic, with the extensions of the window guides Insert 25 into the door box, attach to the window frame 5, through Pre-attach to the sealing-reinforced slip-on strip 8 and fix with the clamping brackets 24 finally on the light metal profile, the window frame 5 sets.

Moreover, in the illustrated embodiment, in particular recognizable in Fig. 1 and Fig. 3, a special design of the window frame 5 such to recognize that the window frame 5 on the B-pillar 15 of the vehicle body facing side by an elongated frame reinforcement part 27 is reinforced. In the illustrated embodiment is provided that the frame reinforcement member 27 as a pressing or deep-drawn part made of light metal / light metal alloys, in particular aluminum / aluminum alloys executed and with the window frame 5 by welding is firmly connected. For the preparation of this compound serves, as shown in FIG. 3, the slip-8 of the window frame 5 in the area of the B-pillar 15. It offers the possibility of appropriate welds or rows of welds to put. Instead of welded joints are also others Connections such as screws, rivets, gluing realizable here, welded joints but will be used normally.

Fig. 3 also shows an embodiment of the attachment in the region of the B-pillar 15 for the diaphragm module 10 such that the diaphragm module 10 on Frame reinforcement part 27 of the window frame 5 by a plurality of clip connections 28 is attached. The attachment of the diaphragm module 10 on the frame reinforcement part 27 requires the rest in this embodiment even closer inspection. The frame reinforcement part 27 is hereby through an insert 35 has been added and reinforced, which carries the openings 36, in which the clip connections 28 can be anchored. In the concrete Embodiment can be about the height of the frame reinforcement part 27 provide a total of three such openings 36 for three clip connections 28. The insert 35 is in U-shaped prepared frame reinforcement part 27 welded. Downwardly parked support legs 37 form a secure reception for positioning when making the weld.

The illustrated design of the aperture module 10 shows different Contours in different sections of the window frame 5, so that for the diaphragm module 10, the production as a plastic injection molding from accordingly motor vehicle typical, weather-resistant and deformation-resistant Plastic recommends.

A further embodiment of the lightweight door according to the invention is also characterized in that as an attachment as a plastic molding, in particular designed as a plastic injection molded roof frame panel 11th from the inside of the window frame 5 is mounted, such that the metal surface of the window frame 5 forming light metal profile close fitting is covered. In Fig. 1, the attachment of the roof trim panel 11 is another Attachment indicated from the inside on the window frame 5, Fig. 2 and Fig. 3 show details of the roof trim 11. Using the inherent elasticity the executed as a plastic molding roof frame panel 11 in conjunction with the realized Hinterhakungstechnik is provided that the Dachrahmenblende 11 the window frame 5 forming light metal profile under inherent elasticity comprises arcuate and at one edge by means of a trained there hook rail 29 or a number of trained there, spaced latching hook is mounted in the receiving groove 7. One recognises as the roof trim 11 around the free surfaces of the window frame 5 forming Leichtmetallprofils nestles and an optimal cover the metal surfaces of the window frame 5 inwards to the interior of the Motor vehicle forms. For further fixation of the roof frame panel 11 on the window frame 5 it is provided that the roof frame panel 11 an opposite Edge of the receiving groove 6 includes hook-like. One recognises This is good in Fig. 2 and Fig. 3. This edge of the roof trim 11 is here from the main seal 9, which sits in the receiving groove 6, covered and in addition fixed.

Fig. 1 shows that in the illustrated embodiment in the roof trim panel 11 a cover 30 for the mirror triangle 26 is integrated.

Figs. 2 and 3 also make a peculiarity of the illustrated embodiment clear, which is characterized in that the window guide seal 21 a the receiving groove 7 overlapping, on one at the Dachrahmenblende 11 trained transition bar 31 passing lip 32 has.

Of particular interest is the correct dimensioning of the receiving groove 7, in the illustrated embodiment, ie the second receiving groove 7 next the receiving groove 6 for the main seal 9. The receiving groove 7 is so dimensioned that the locking bar 29 of the roof frame panel 11, the clamps 24 of the diaphragm module 10 in the receiving groove 7 against falling out fixed. In fact, the two elements are mutually exclusive against slipping out of the receiving groove 7 fix. Is covered the entire mounting area through the lip 32 on the window guide gasket 21st

Fig. 3 leaves the area of the window frame 5 on the B-pillar 15 with the B-pillar panel 20 recognize. There, where the window frame 5 to the inside of the Car body is turned, you can see a the receiving groove 6 forming Recognize edge 33. This edge 33 is as well as the opposite Edge in the door box 1 at a location where a holder of the main seal 9 is no longer necessary, but a lock plate immediately snugly should run. Here is the inlet of the window frame 5 in the Sheet metal of the lock carrier done. From here, the edge 33 and the mounting strip 8 be unlatched. For this purpose, a preferred teaching is provided here, that this edge 33 of the adjacent edge 34 of the window frame 5 forming light metal profile is set back, with this edge 34 rounded with a matching to the wall thickness of the profile material radius is. This makes it particularly clear in FIG. 3. Will the edge 33 here Notched, so there is virtually no burr, at least a ridge of the Edge 34 set back and does not hinder a whopping and optimally running Installation of the lock plate or the Türinnenwandung in the area of Edge 34.

Finally, FIG. 1 makes a preferred manufacturing method for an inventive Lightweight door, which is characterized by already on the door box 1 firmly attached window frame 5 in a first process step the main seal 9 on the door box 1 and the window frame. 5 is attached, in a second process step, the roof trim panel 11 is attached to the window frame 5 and clipped, in a third Step the panel module 10 is inserted into the door box 1 and in a fourth method step, the diaphragm module 10 on the window frame 5 at already fixed there roof frame panel 11 with clamps 24 in the receiving groove 7 and the frame reinforcement member 27 with clip connections 28 is clamped.

Claims (16)

1. A lightweight door for motor vehicles,
   with a door casing (1), the upper section of which is delimited toward the window surface by inner and outer window shaft profiles (3; 4), and with a window frame (5) made of light metal/light metal alloys, particularly aluminium/aluminium alloys, that encloses the window surface and is permanently attached, particularly welded, to the door casing (1), particularly to the inner window shaft profile (3),
   wherein the window frame (5) is realized in the form of an extruded and bent, particularly a stretch-bent, light metal profile,
   characterized in that
   at least one essentially continuous receptacle groove (6; 7) following the profile progression and/or at least one essentially continuous clip-on strip (8) following the profile progression is provided on the light metal profile forming the window frame (5) and serves for receiving, attaching or connecting an add-on part (9; 10; 11; 27),
   the light metal profile forming the window frame (5) contains a closed hollow chamber (12), on the outside of which the receptacle groove (6; 7) and/or the clip-on strip (8) is or are arranged, and
   an add-on part consists of a panel module (10) that is realized in the form of a moulded plastic part and arranged on the outside of the window frame (5),
   wherein outer panels (19; 20) are integrally formed onto the roof frame (13) and onto the B pillar (15) in the panel module (10) and at least one window guide seal (21) is attached to the panel module (10).
2. The lightweight door as claimed in claim 1, characterized in that
   an outer window shaft seal (22) is also attached to the panel module (10) and/or
   the panel module (10) has the cross section of a U-profile with an adjacent L-profile.
3. The lightweight door as claimed in claim 1 or 2, characterized in that
   the panel module (10) for being attached to the window frame (5) rests on a support surface of the light metal profile forming the window frame (5) with a support surface (23) and is mounted in the receptacle groove (7) by means of a plurality of clamps (24) that are spaced apart from one another, wherein the clamps (24) are preferably realized in the form of metal spring clamps.
4. The lightweight door as claimed in any one of claims 1 to 3, characterized in that
   the panel module (10) is attached to the clip-on strip (8) with a clip-on receptacle, particularly with an seal (17) arranged in between, and/or
   the panel module (10) is provided with extensions of window guides (25) that can be inserted into the door casing (1) and project downwards over the window shaft profile (4) and/or
   a mirror triangle (26) is integrated into the panel module (10).
5. The lightweight door as claimed in any one of claims 1 to 4, characterized in that
   the window frame (5) is reinforced on the side facing the B pillar (15) of the motor vehicle body by means of an elongated frame-reinforcing part (27),
   wherein preferably the frame-reinforcing part (27) is realized in the form of a pressed part or deep-drawn part made of light metal/light metal alloys, particularly of aluminium/aluminium alloys, and rigidly connected to the window frame (5) by means of welding or another method.
6. The lightweight door as claimed in any one of claims 1 to 4 and claim 5, characterized in that
   the panel module (10) is mounted on the frame-reinforcing part (27) of the window frame (5) by means of several clip connections (28).
7. The lightweight door as claimed in any one of the preceding claims, characterized in that
   the door casing (1) has an essentially U-shaped supporting frame that is preferably realized in the form of a pressed part or deep-drawn part manufactured in one-piece from a panel with minimal panel thickness that is made of light metal/light metal alloys, particularly of aluminium/aluminium alloys.
8. The lightweight door as claimed in any one of the preceding claims, characterized in that
   a T-shaped seal receptacle groove (6) is provided for attaching an add-on part in the form of a main seal (9) on the door side.
9. The lightweight door as claimed in any one of the preceding claims, characterized in that
   a T-shaped add-on part receptacle groove (7) is provided for attaching mounting elements of add-on parts (10; 11),
   wherein, preferably, the add-on part receptacle groove (7) is arranged obliquely relative to the seal receptacle groove (6) if such a groove is provided.
10. The lightweight door as claimed in any one of the preceding claims, characterized in that
    a clip-on strip (8) is provided, particularly for attaching an additional seal (17),
    wherein, preferably, the clip-on strip (8) projects at an approximate right angle from the seal receptacle groove (6) for the main seal (9) if such a groove is provided.
11. The lightweight door as claimed in any one of the preceding claims, characterized in that
    an add-on part consisting of a roof frame panel (11) in the form of a moulded part, particularly an injection-moulded plastic part, is attached from the inside to the window frame (5), particularly such that the metal surface of the light metal profile forming the window frame (5) is tightly covered,
    wherein, preferably, the roof frame panel (11) encloses the light metal profile forming the window frame (5) in an arc-shaped fashion and is mounted in the receptacle groove (7) on one edge by means of a hook strip (29) formed thereon or a series of spaced-apart hooks formed there,
    wherein, further preferably, the roof frame panel (11) encloses an opposing edge of the receptacle groove (6) in a hook-like fashion.
12. The lightweight door as claimed in claims 4 and 11, characterized in that
    a cover (30) for the mirror triangle (26) is integrated into the roof frame panel (11).
13. The lightweight door as claimed in claim 11 and, if applicable, claim 12, characterized in that
    the window guide seal (21) has a lip (32) that covers the receptacle groove (7) and transforms into a transition strip (31) formed on the roof frame panel (11).
14. The lightweight door as claimed in claims 3 and 11 and, if applicable, claim 12 or 13, characterized in that
    the hook strip (29) of the roof frame panel (11) fixes the clamps (24) of the panel module (10) in the receptacle groove (7) from falling out.
15. The lightweight door as claimed in any one of the preceding claims, characterized in that
    an edge (33) forming the receptacle groove (6) and/or a clip-on strip (8) are sectionally notched,
    and this edge (33) or this clip-on strip (8) is set back relative to an adjacent edge (34) of the light metal profile forming the window frame (5),
    wherein this edge (34) is rounded with a suitable radius for the wall thickness of the profile material.
16. A method for manufacturing a lightweight door for motor vehicles as claimed in claims 8, 9 and 11, characterized in that,
    with the window frame (5) already being rigidly attached to the door casing (1),
    the main seal (9) is attached to the door casing (1) and to the window frame (5) in a first procedural step,
    the roof frame panel (11) is attached and firmly clipped to the window frame (5) in a second procedural step,
    the panel module (10) is inserted into the door casing (1) in a third procedural step and
    in a fourth procedural step the panel module (10) is rigidly clamped to the window frame (5) with the roof frame panel (11) already mounted thereon, preferably with clamps (24) in the add-on part receptacle groove (7) and with clip connections (28) on the frame-reinforcing part (27).

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